Made in America – Changing Designs

As the global supply chain challenges are still with us we, like many, are finding ways to re-tool some hardware designs so that we are not reliant on overseas suppliers.  All of our work, meaning our castings are made locally by us here in Los Angeles. From the initial creation of the pattern to mold development, to pouring wax and then bronze or steel the process is local and the materials if not local are certainly American made.

There is one area though where we have relied on LED components in our illuminated door handles and so are transitioning away from lighting our handles to finding more creative and less high-tech ways of adding a dash of sparkle to designs, which in their own right, do not actually need embellishing. Simply put we are phasing out colored LED and replacing this with powder coating.

Benefits of new direction

The main advantage is the flexibility with which a piece can be powder coated. Powder coating can be applied to almost any part of a handle which allow for color to be integrated in a much more artistic and organic way. This is especially the case with the Morphic pieces.

When we created the LED pieces we had assumed that eventually we could move away from direct wired electric power to  long life batteries that would be small enough to fit inside the fixture. This did not occur and the resulting market was very small.

By moving away from LED products we are able to lower the consumer price just a little as we no longer will be buying the components and we will no longer be paying the costly testing and regulatory fees charged by UL.

Animal Knobs - Bees, Lizard and Dragon Designs

All are part of the Netsuke Collection, named for the contained round shapes of its members that are similar  to their namesake used in clothing as fasteners.

Bee

The shape of the bumble bee is inherently round but in our artistic representation these attributes have been exaggerated for a more whimsical appearance. That said, we share with many a deep respect for this prodigious insect who is central to the pollination of plants and whose honey I enjoy on a daily basis.

Back in March 2019 we observed a swarm of bees that landed and rested in our Brazilian Pepper Tree along their way to create a new nest for their Queen bee.

 Recently we added another smaller bee to our collection of  flying insect cabinet knobs and again have rounded the contours of this piece to create an easy and pleasing to grasp cabinet pull. In an earlier post you can follow the development of this piece from initial sketch to fully fledged casting.

Lizard

The Anole lizard was the specific lizard that we modeled our door knob on. We chose this species as it has beautiful green tones that we could simulate by carefully applying a … patina to the lizards body and tinny toes.  The lizard as with all our Netsuke door knob sets can be mixed with different animals on either side of the door. Many of our door knobs can be used creatively by mixing different styles in one door set. To see how designer Hilary Zeiss playfully mixed 2 different animals please visit our blog posted on June 4th, 2021.

Dragon

The dragon is the most recent addition to this collection and is my personal favorite.

Detailed Door Hardware

Occasionally we have the pleasure of working with a design company that shares the same detail-oriented focus and commitment to exceptional door hardware as we do. Over the last year we have had the pleasure of working  with Chiara de Rege and her all female team to develop custom pieces for her discerning clients. Based in New York, the company’s clientele spans both coasts with design services for residential and corporate clients.

 Our collaboration with Chiara de Rege  on an Upper East Side residence resulted in the creation of a unique collection of door push plates and door levers. The traditional  Willow series was whimsically re-invented and enhanced with flying creatures from our animal  collection of cabinet knobs. The resulting door push plates and interior door handles were selected from several initial designs that paired smaller insect, bird and frog pulls with the Willow back plates.

The design team were renovating a residence using the existing doors that had astragals and panel mullions  that reduced the workable free area of the door and limited the backset depth of the latch.  With these considerations in mind, we focused on the Willow and Hedgerow exterior backplates, both being narrow and having smooth areas that could be enhanced by the addition of a small creature .

 

Some of the designs considered are shown below. Once the design genie was released, we had a lot of fun experimenting with different cabinet knobs and with insects flying in different direction. While our preference and that of Chiara’s design team was on flying insects, leaves and flowers could work equally well for those who have an insect phobia.

 

Happy Labor Day

While we humans may get a break from work those in the larger animal kingdom will still be buzzing and digging as they toil to create  honey and dung balls!

Our new sculptures include a dung beetle and Martin is currently creating an artistic portrayal of dung  beetle ball which will be the latest addition to his bug themed sculpture  series.

Our bees are still thriving in bronze and those who follow this blog know that we have recently added a bee cabinet knob to our flying creature collection of cabinet pulls.

Our fascination with bees was piqued by a book we are reading “An Immense World” by Ed Yong in which he devotes a chapter to the electrical world we live in. The planet’s daily thunderstorms are prolific running into the thousands and they create a massive electric circuit where the earth is a negative  and the air a positive charge. Bees buzz in this electric field passing by flowers who because they contain water are rendered negative or grounded. As bees fly through the air, they assume the positive charge of the air around them and when they land on a flower to suck nectar the negative pollen is attracted to the bees negative force and literally rises up towards the bee. For those able to remember their early science classes, this electric attraction is similar to what we observed as children when a magnet was used to pick-up iron filings.

Returning to the theme of this blog, labor day is not a holiday celebrated by bees or dung beetles both of which will be working overtime during this 3-day holiday.

Floral Developments – Simple Mold Making Lost Wax or cold cast resin

In the previous post we documented the designing and pattern creation process for our new large orchid pull. Next, we make 3  two-part molds, one for each of the stamen, labellum, and petals.

Our mold is made using a 2-part silicone rubber solution Mold Star distributed by Reynolds Rubber.

The wax sections are assembled so that we will have template to guide how we weld the 3 parts.

Mold Star is available in different degrees of pot life, meaning the amount of time it takes before the mixed solution sets. Mold Star 16 has a shorter pot life and quicker curing time than Mold Star 15 and is the rubber we prefer using. For large area with more volume of rubber we add another Reynolds product, Slo-Jo that slows the curing time. As the silicone rubber is curing and especially for larger dense molds there is a tendency for gas pockets to form. The pockets may not be visible but when wax is subsequently poured into the silicone mold the pockets will create small holes in the wax. To prevent this, we place the thoroughly mixed silicone into a vacuum chamber and pump out the air and gases that form and when the remaining bubbles are extremely small, we then pour the solution over our pattern to create the mold.

The 3 sections will be cast separately and will be welded together once cast

These are simple 2-part molds that most hobbyists could make with a little time and practice. As the patterns are not too deep, they will be cast in solid bronze rather than as hollow castings. Our molds are used to create wax replicas for use in lost wax casting but the same type of mold could be used to create fiberglass or resin pieces. Gates and a central sprue are added to the pattern and these will become  the channels for the poured bronze. The gated pattern is placed in a tight-fitting container and the silicone solution is poured over it and left to set. Once set, we insert a sharp blade into the side of the mold and cut around the outer edge and gently pull the mold apart to release the pattern. The cavity that has been formed around the pattern is then filled with hot wax which passes through a central hole in the mold. The 2 halves of the mold are firmly held together with 2 pieces of bolted plywood that will keep the mold rigid when the wax is being poured. Once the wax has set the plywood is unbolted, the 2 parts of the mold are pulled apart and the wax replica is ready to be shelled. If you were casting your piece in resin, you would omit the gate and sprues and your product would be complete after the resin had set.

2 Part mold for petals these are held together with bolted plywood when wax is being poured

The orchid is assembled in wax as a guide we will use when welding the bronze sections together. The piece could not be cast as a single flower as there are too many undercuts and the bronze would not pour easily.

Bolts keep the 2 plywood formers in place while red wax is poured

New orchid design for dramatic entry door takes shape

Our Orchid cabinet knobs and pulls are popular pieces and often used as accent statements in kitchens and bathrooms. I suspect the appeal lies in their realism although the designs are not a literal portrayal of any particular orchid. The closest type of orchid is possibly the Paphiopedilum (Venus Slipper) or the Phalaenopsis (Moth) but with over 20,000 species and hybrids there may well be and exact match that left it’s imprint on Martin Pierce’s retina.

 Orchid Cabinet Knobs and Stems

The orchid knob has a 3/4” stem post that allows the flower head to be easily gripped and pulled. The same clearance for fingers is given to the orchid spray by the curved stem that connects the 2 orchid flowers.

New Orchid for grand statement

The new orchid is scaled to make a dramatic door statement and like our Willow heroic pull we see it being placed in the center of the door and not on the door stile. The end result will be cast in solid bronze and measure 6” x 6” x 1 ¼” and it may lend itself to being either nickel plated or artistically patinaed with differing hot green, red or yellow oxides. Unlike the smaller cabinet pulls there will not be a stem post mounting as the orchid perimeter petals will be flush with the door face. As the orchid is loosely based on the Venus slipper orchid it has a large stamen and labellum and together these will serve as the gripping point for the thumb and index fingers.

 Martin as readers will know begins a new piece with a front and side view drawn free hand on paper and this becomes the guide used to roughly cut the patterns in high density foam. The drawing details are then copied on to the rough patterns and then carved to create a three-dimensional piece. The new orchid will be cast in 3 pieces which will be welded together to create a single knob.

 

On line art gallery

We are expanding our on-line presence for our insect sculpture collection some of which can now be viewed on www.onlinegallery.art

This new venture will hopefully encourage readers to peruse the art work of other artists on a site that offers a wide range of mediums, subjects and styles.

Too date the Hornet on the Apple shown below and the Stag beetle have been added to online gallery with more pieces coming soon. In our fictional world humanoids may playfully spar with hornets for grazing rights to an apple but thankfully the hornets dominance is secured by it’s greater armory and strength.

In this same fictional reality stag beetles often provide transportation and other services for their humanoid friends but their relationship is symbiotic not exploitative and both species enjoy the fruits of each other’s labor.

4th JULY

4th July - Enjoy the long weekend

We are celebrating the 4th quietly in the company of good friends and hope all of our customers are able to do the same.

The hornet on the apple is a limited edition sculpture that we have playfully draped with the US flag.

The sculpture is one of several art pieces that can be found on our new site pages so please check them out.

If you are remodeling your home or fortunate enough to be designing a new home then please check out our wide variety of custom cabinet pulls and unique door handles Like all of our castings we are proud to make everything here in Los Angeles.

Back plates and Push plates

When is a back plate a push plate? This is an interesting and easy question to answer and the correct answer is whenever the plate is  large enough, wide enough and flat enough to easily push open a hinged swinging door.

Now that we have established the rules it becomes clear that most entry door escutcheons can be used as push plates provided they are ordered for this function.

Hedgerow and Willow

Both collections have 22” high backplates where the decorative component is limited to the outer top and bottom edges leaving a flat unencumbered area of 14” that is more than enough to accommodate the palm of a hand.

We make all of our work to order and tool our back-plates after the plate has been cast. In so doing our back plates can be later machined to create a hole for a cylinder lock or thumb latch or can be left as a flat plate to function as a push-plate.

While both collections have elegant back plates that need no further adornment, we have begun re-imagining both with more whimsical additions.

Ergo minimalism

The simpler backplate is smaller at 12” and while it does not lend itself to whimsy the fact that the entire plate is unencumbered allows it to function well as a more understated push plate. The Ergo collection is available in stainless steel or bronze.

Vine and Bark Back Plates

Both entry plates are adequate in size and in my opinion would work equally well as push plates as while they are extremely textured the filigree does not protrude too far or have any areas that could catch on clothing.

Living Patinas thrive in Northern California Seafront Home

Photographing sculptural hardware out of doors and relying on natural light to do so is  a daunting task. The time of day, cloud layer and sun position have to be balanced and each photo has to correctly frame the scene.

We were fortunate to work with a client who commissioned our Morphic cylindrical bronze handle for all of his exterior doors in a new home he and his wife were building on the coast close to Fort Bragg.

The clients began with 2 sets of handles and once they were  installed decided to use the same style for all of their doors. The stand-offs  for the outside sets were modified and shortened so that they would not collide with the shutters when closed and the client had the foresight to make a mock-up of the handle so that he could determine the precise length for the posts. As art collectors the clients understood that bronze reacts to air, sun, salt, and a multitude of other environmental factors and over time will develop a film of oxide on its surface. This holds true even if the piece has been patinaed before installation as the patina will continue to develop in response to local conditions.

Photo courtesy of a wonderful client - thank you for permitting this use

Perfectly framed and naturally lit

We finished these pieces using varying strengths of a mildly acidic solution over differing sections of the pull. We then re-burnished areas to highlight the natural bronze before sealing with a clear wax. While clear wax does slow oxidation it does not prevent the living patina from evolving with some areas becoming darker and other areas lighter where they are naturally re-burnished through use.

An oil rubbed finish possess an organic beauty that can easily be maintained by a home owner. If the finish becomes too dark, then gently rubbing the bronze with a medium grade scotch brite will return it to its original golden appearance. When using the scotch brite pad make sure to do so gently and in a non-directional circular motion to avoid scratching.

Willow back-plate note brightness of leaves Select areas were re-burnished

 

A new sculpture compliments Martin Pierce's original door hardware

To date Martin Pierce’s collection of fictional insects and entomophile humanoids sculptures has introduced us to stag beetles, wasp, hornets, and Jay birds, today we introduce the dung beetle.

The piece has moved from pattern and mold making to bronze and to a discussion of appropriate patinas and new pieces that will be associated with the dung beetle. The story line is developing to include family members and to a fictional portrayal  of this scarabs dung dwelling. Artistic license is playing a  role, so Martin is giving all adults horns even though in reality this attribute varies between species. The dung beetle is a semi-fossorial animal meaning it is a creature that has developed the skills and anatomy to dig and live some of its time underground. Consequently, the beetle has a strong compact body, bulldozer shaped head and 2 stout tooth like front digging legs for burrowing into dung. The remaining 4 legs are longer, more segmented and end in a serrated saw-like claw. This complicated organism is extremely dexterous and able to coordinate all 6 legs to walk, to  create a dung ball then manipulate and roll  the ball backwards and even bury the ball for offspring in the case of a brood ball. If that is not it enough, consider that it can also fly and that below the polished smooth wing casings are 2 powerful wings that can lift this small but heavy creature taking it to new feeding grounds.

In Martin’s fictional world the dung beetle co-exists with humanoids and when not caring for his family members helps till the soil and aerate the fields for seasonal crops for humans. The 2 species also collaborate in the annual insect race where humanoids act as riders and navigators to steer the backward moving beetle to the finish line. These scenes as well as other family members are hopefully going to take shape in sculpture and paintings over the next few years.

 

Wine Cabinets – Hardware Discussed

For serious wine collectors keeping those liquid gems at a temperature and humidity  where they live happily until consumed is a crucial factor both in the design and construction of a wine closet and in  choosing suitable door hardware.

LEFT: Doors with tubular latch cabinet center divide RIGHT: Fixed handles cabinet doors flush no divide

Wine kept for future consumption needs to be in a cool dark cabinet that is kept to a temperature of 45-65 degrees with a controlled humidity of about 70%. It is also important to keep wine free from vibration as this will disturb the sediment in the bottle as well as setting off a chemical reaction that decreases the wines acids thereby dulling the wines flavor. While minor vibration may be easier to control, in California the vibrations are often seismic!

Do the specific requirements for wine storage limit the customers choice of door handle?

The simple answer is no, choosing the right type of handle for a wine cabinet door should be no more taxing than selecting a handle for any interior door. The same factors need to be considered and questions answered;

Door handing

Functioning latching handles versus fixed

Width of door stile

Door Handing

Looking at the door from the outside, doors that hinge on the left are left-handed and those that hinge on the right are right-handed and this holds true for double doors. Some wine closets are made with a pivot hinge that attaches to the top and bottom of the door with a pin rod, see photo below.

Whatever the hinge type it needs to be strong enough to ensure that the door(s) when closed, tightly fit into the cabinet frame to help maintain a constant temperature. Wine cabinets and wine racks are often made to pitch backwards  which helps prevent the wine from touching the cork and also gives a gentle gravity tug that helps the doors to firmly close.

 Functioning or non-operative levers/pull

This brings up the question of cabinet construction and the presence of a center divide. A center divide is a wood divide that runs from the top to the bottom of the cabinet frame. A center divide of at least 1 1/2”is critical for double doors if they are required to latch with a tubular latch. A tubular latch is activated by the lever which throws the latch tongue into the strike on the side of the divide. Cabinets can be made with  a hydraulic hinge closure which creates a tight hermetic seal that does not require a latching operational handle. If  the double doors are flush without a divide then magnetic latches attached to the top and bottom of the doors and cabinet frame are a good option. Roller latches are another option but the roller ball and strike tend to wear out and the roller springs tend to loose their tensile strength so will need to be adjusted periodically. The plan view in the above diagram shows how the tubular latch and magnetic differ.

Stile Width and Backset

Our standard backplates are 3” wide and require a net stile width of 5” for a 2 3/8” backset. For smaller stiles our multi-point backplates are 2 1/8” or 2 ¼” wide and require a 3 ½” net stile. The width is referred to as net to denote the free flat surface of the door frame without any door molding or astragal.

Photos courtesy of Susan Diamond Location Residence of Susan Diamond and Andrew Fletcher

Hedgerow Multi-point Sets Used as Fixed Handles

 I wrote this piece in response to a consumer whose tenacity and diligence proved indispensable in the correct ordering of our vine door handles. Ordering door handles should not require a degree in engineering and should not be an arduous task so my advise is to check and double check the door specs supplied and don’t hesitate to ask the hardware manufacturer for help in ordering the right type of handle and latch.

Exterior Door Handles – Lock Types & Door Preparation

Unravelling the words used to describe simple door handles.

I recently spoke to a modest but tenacious person who had decided to purchase a door handle set for her new wine cellar. She had spent the previous week grappling with the odd terminology of door handing ,lock backset and door stile and was now ready to place her order.

Exterior doors are made secure by locks that vary in price, strength, and degree of difficulty when being installed. Our handles can be configured for a wide range of locks so choosing the type of lock should not be a barrier to buying whatever style of handle you like. Word of advise, make sure that any lock that is installed on location is done by either a qualified lock smith or competent contractor.

 

3 Types of door locks not including electric and digital  locks

Keyed Cylinder – a simple way to lock the door with minimal door preparation. A 2” hole will typically be cut into the door by the door manufacturer. You will need to understand the term backset which is the distance from the side or edge of the door to the center of the cut hole and can be anywhere from 2 3/8” to 5”. The distance will largely depend on the width of your door stile, which is  the flat area of the vertical door frame  and typically 2 3/8” or 2 ¾”. The cylinder on the outside of the door is activated by your key which when turned throws a  metal tongue into the door jam. The key throws the lock usually when it is turned clockwise and retracts it when turned anti-clockwise. On the inside of the door the turn piece performs the same function of throwing and retracting the tongue. This type of lock also has a double keyed cylinder option and a key is used to activate either cylinder.

Mortise Lock - Arguably the strongest type of lock this requires a lot of door preparation ideally performed by the door manufacturer. Here a very sturdy good gauge of  steel is used by the lock manufacturer to create a box that houses the intricate locking mechanism and from which a large heavy duty latch and bolt are released. We use the Accurate mortise lock box that is approximately 6”H x 3 ½”W x 7/8”D.

The mortise lock and keyed cylinder locks both release a metal tongue approximately 1” into the door jam for a single door or the non-operating door in the case of a double door.

Multi-point - This type of lock also provides a high level of security achieved in part because the mechanism throws 3 bolts, one into the top the door jamb one into the door sill and the third into the center of the door jamb or other door if this is a double door. Like the mortise the mechanisms are housed in a central metal box. The top and bottom bolts are typically ½” flat rods that pass through a pre-cut channel that runs the length of the door. As this type of lock requires extensive door preparation the doors are usually sold with the lock already installed.

The multi-point lock box and escutcheon that cover it are usually narrow and I am guessing this is because they are used on French doors aka patio doors designed with glass pane(s) for maximum light. Whatever the historical reason, like most hardware makers, we offer a narrow back-plate to suit this type of lock for most of our door handle collections.

 

Developing an Art Collection

Developing an Art Collection  - The Land of Giant Insects

 

In 1999 Martin Pierce began a journey into bronze casting with 8 collections of door hardware and cabinet pulls. Forward to 2022 where the road has forked, and a wide tributary is winding its way to a collection of art sculptures.

Martin Pierce and his first collection have just been featured on Artsy Shark, a site that  helps  promote artists and their work. While the fictional story behind  this collection is ongoing, we thought it timely to begin telling the tale and  by explaining the fictional landscape and it’s characters.

A Tale of Giants and Insectophile Humans  -

In today’s world, insects and birds lack the social and environmental importance they deserve. Humans in this world dominate the planet and their demands are contrary to the well-being of other species. In the new and  fictional world, Martin Pierce, through sculpture and painting reverses the relative size of humans to insects with the former becoming diminutive and the latter becoming giants. The fictional scale also gives rise to a new relationship and the adversarial human is reinvented as an insect loving humanoid. While the relationship between these 2 species continues to evolve it is built on an agrarian lifestyle where humanoids and insects farm together and jointly partake in the fruits of their labors.

Landscape

The landscape is one of mangroves, yuccas, and bougainvillea with swaths of land cleared for farming. The topography is varied with craggy cliffs and rolling hills and lower lying valleys and swamps.

Characters

Grasshopper – resting on a mushroom and casting his stupendous shadow over the humanoid hiding in the mushrooms spongy fold. Both characters make their appearance in annual sporting events.

10”W x 9”D x 14”H

Stag Beetleat least 2 varieties exist, the shiny suave steely and darker mottled bronze.  They too compete in annual events but also play a key role as farmers  tilling the soil ready for planting. The stag beetle makes his sculptural appearance as a runner sometimes accompanied by a humanoid rider and as one of 2 adversarial beetles sparring on a piece of oak bark.

20”W x 15”D x 6”H

Hornetshown feeding on a large apple with an irritating humanoid for company

13”W x 10”D x 13”H

Wasp – portrayed as a solo runner or accompanied by a humanoid rider

11”W x 8”D x 6”H

Jay – flying toward the east or toward the west

17”W x 12”D x 4”H

Dung beetle and Raven – following soon

 

Beetles in the fictional world of Martin Pierce

A lesser-known area of Martin Pierce’s work is the fictional world occupied by insect and humanoid bronze creatures. To better show these sculptures we are adding new pages to our site and will be creating a new collection page and eventually a payment portal.

Since childhood Martin has been  fascinated by  insects and birds and not just by their obvious beauty but by their ingenuity and dexterity. Wasps, butterflies, moths, and swallows are represented in our company’s door hardware and cabinet hardware collections. However, the scale of  door hardware as well as the functional limitations relegate these forms to incidental turn pieces, thumb latches or cabinet pieces. 

As Martin’s art work is not subject to the same restraints he is using this new freedom to re-imagine both the scale of humans to insects as well as their functional and social relationships.

In December 2021 Martin sourced a deceased aqua blue horned rhinoceros dung beetle from a New Mexico  entomologist. Known affectionately to friends  as Phanaeus Pilatei this particular insect is beautifully colored and powerfully built. The powerful front plate and horn is used as a soil digger that is as proportionately powerful as a bob-cat shovel or bulldozer blade.  Alas, the beauty and mechanical dexterity of Phanaeus is rarely appreciated due to his diminutive size. In Martin’s sculptures and paintings he hopes to shine a light on these undervalued scarabs by portraying then as larger than life and by developing a story that he hopes will be captivating.

True size of Dung beetle 3/4”L x 1/2”H New Model for Dung Sculpture 10”L x 6”H Other Beetle Sculptures

Dragon

The first dragons have emerged from the fiery pit of the foundry and have matured into full fledged beautiful door handles. We have enjoyed seeing these fiery monsters take shape and hope others will enjoy the whimsy of this new piece. A new dragon page has been added to our website and the new family member takes the center spot on our Netsuke page where you will find other animal knobs.

All of our work including our  fanciful pieces must also meet the functional demands of door hardware. To make the dragon casting into a functioning door handle it was fitted with a pre-machined  ferrule that was welded to the open end of the dragon. The inner section of our ferrule is machined to fit an 8mm square spindle. The spindle serves as a connecting rod and allows 2 knobs to be connected to make an interior door set.

The dragon rose will be used as a cylinder, turn piece or knob rose and the center area will be machined according to the size of the center hole needed.

 

The rose uses scaly dragon knuckles to create 4 decorative rows that meet in the center.

 For the dragon’s turn piece we looked to the Willow collection and found the bundle of Willow leaves to be a perfect match. We were considering a turn piece shaped as a hooked dragon toe but think this may be too kitsch of a statement.

What is the difference between a cabinet pull and an appliance pull

A common question is whether you can or should use a cabinet pull as an appliance pull. The question has 2 components  one is  aesthetic and the other technical-mechanical.

Larger Morphic Pull has a lip overhang that is easy to grip with whole hand for heavier doors and drawers

 Mounting posts - distance between centers – screws

A typical pull be it for a cabinet or appliance door will be attached by 2 screws that thread into either a mounting posts or  recessed holes on the back of the pull. The hardware manufacturer determines the location and distance between the posts, the size of the pre-drilled holes and the type of screw or bolt used to attach the pull. These factors together with the heft of the pull largely determine whether a smaller cabinet pull will work satisfactorily as an appliance pull. The mounting posts on our cabinet pulls are generally placed a little below the top and bottom of  the casting and are part of the casting. Their size is scaled proportionately to the size of the piece but at a minimum needs to be large enough to accommodate an 8-32 screw.  To work as an appliance pull for a large refrigerator or sub-zero door the posts will need to accommodate a more substantial 10-24 or even ¼-20 screw. As we make a wax replica before casting we can  customize the post making it larger or by making the area for the tapped hole larger. The thickness, thread count per inch and length as well as the base material all impact the strength of the screw. The thickness of the screw or the outside dimension of the threaded shaft is the first number given and is expressed either as a size or as a fraction. Smaller thinner screws are typically given a number and those greater than ¼” are usually expressed as a fraction 5/16”. The second number for a machine screw is usually the threads per inch followed by the length. For wood screws the thread is not called out and only the thickness and length are given.

The base metal of a screw will impact it’s strength and while brass screws are more decorative, unless they have a wide diameter will not be as strong as a stainless steel screw. Stainless steel has a greater tensile strength, is harder and the thread is not as prone to being stripped when under pressure.

10/24 x 3” #10 size screw diameter of threaded area is 3/16”, there are 24 threads per inch and the screw is 3” long. The style of screw is Slotted SLTD with a round head and it is a machine screw.

6 x 5/8 is a # 6 screw diameter 9/64” as it is a wood screw no thread count is given for this 5/8” long screw that has a Philips Oval Head style.

1/4-20 x4” the screw diameter is being shown as a fraction not a number code. This is a 1/4” threaded screw with 20 threads per inch it is 4” long and is a machine screw with a slotted head. The base metal is 18-8SS stainless steel which is equivalent to 304 stainless steel.

Note the heft of the ends of this pull they are in solid bronze and approx. 1 1/2”D x 1 1/4”H ideal for heavy gauge bolts

Aesthetics and Costs

Assuming the cabinet pull meets the technical demands above whether to use it as an appliance pull largely depends on taste and budget. Stainless steel and bronze are premium expensive metals and their prices continue to rise. Clearly an appliance pull will require a lot more metal to make and a lot more time to finish.

Custom door hardware - an index of posts on the process

Over the years of writing my blog I have often described the process from designing to casting door hardware using the lost wax method but have not until now felt it necessary to index  these posts.

The posts are broken down into 5 areas that describe the process from inception to end product. If you have limited reading time there is one piece that covers most of the stages that was was posted on June 21st 2017.

For details on the different stages please read on.

STAGE 1 - Design

These posts follow the creative process from the initial sketch to more detailed drawings that show the piece from different perspectives. They explain how the technical aspects of lost wax casting as well as the functional requirements of door hardware impact the design and result in modifications to the original concept.

https://www.martinpierce.com/blog/dragon-and-netsuke-door-knobs

https://www.martinpierce.com/blog/custom-designed-door-hardware-some-common-misunderstandings

https://www.martinpierce.com/blog/early-designs-for-a-new-entry-door-pull

https://www.martinpierce.com/blog/candlesticks-new-designs

https://www.martinpierce.com/blog/new-morphic-door-pull-one-size-does-not-fit-all

Stage 1 - detailed drawing from 2 perspectives Stage 2 - rough carving of pattern later refined

STAGE 2 – Pattern making

Lost wax casting requires an  original pattern or sculpture to be created. We create our patterns by sculpting  in a hard wood, blue wax or high-density foam. Our method is reductive and rarely makes use of 3D printing and we explain why in these posts.

https://www.martinpierce.com/blog/bumble-bee-cabinet-knob

https://www.martinpierce.com/blog/dog-door-knobs

https://www.martinpierce.com/blog/new-carp-fish-door-pull

https://www.martinpierce.com/blog/why-research-and-development-costs-for-custom-hardware-is-expensive-part-2

https://www.martinpierce.com/blog/3d-printing-as-useful-tool-in-casting-custom-door-handles

STAGE 3 - Mold making, gates and sprues

A mold of the pattern is made. The number of molds needed for one design depends on the complexity of the design and in assessing how the molten bronze will flow. The pattern is fitted with one central sprue and several gates that attach to the sprue and the edge of the pattern. A mold (s) is then  made of the pattern with the sprue and gates attached.

https://www.martinpierce.com/blog/how-to-make-a-simple-mold-for-lost-wax-casting

https://www.martinpierce.com/blog/how-to-cast-bronze-butteflies-good-and-bad-runners-and-gates

STAGE 4 – Wax replicas and shelling

The lost wax method requires a wax replica to be made for all the component parts needed to make one piece. The Hedgerow door lever for example require 4 waxes to be made; one for the escutcheon, one for the lever, 2 for the tree canopy. The waxes are then dipped in a silicone slurry that when hardened forms a shell that encases the wax. An auto-clave is used to remove the wax (lost wax)  and the hollow shell is ready to receive molten metal.

https://www.martinpierce.com/blog/wine-cellar-door-handles-and-shell-casting

https://www.martinpierce.com/blog/using-wax-facsimiles-to-create-bronze-door-handles

 https://www.martinpierce.com/blog/hawaiian-theme-door-handle

https://www.martinpierce.com/blog/creating-a-custom-appliance-pull-using-the-lost-wax-process-the-wax-stage

 https://www.martinpierce.com/blog/limited-edition-door-handles

Wax replicas ready to be shelled

 

Creating a simple bracket to secure a door lever

Now that Jackson, our latest Pitbull family member has turned one we realize that his name needs to be changed to Houdini! We had thought our front garden gate was a sturdy secure barrier that would keep us safe as it is fortified with a mortise lock made by Accurate, the industry leader in security locks. What we had not foreseen was that the gate could be opened from the inside by a cunning canine capable of standing on his hind legs while using his front paws to depress the gate lever.
If our dog training had been more successful and the commands of “come” and “stay” had worked then we might have been amused by his antics.
We installed Accurate’ s 9148 series mortise a well-designed mechanism that has an egress rocker that allows you to keep the gate unlocked, a useful function when your spouse is at home, and you want to pop out for a stroll. Faced with this unexpected problem our choice was to either replace the lever with a knob set and install a new mortise or find a way to outsmart Jackson. We chose the latter option as we enjoy our lizard entry set and so designed a simple restraining bracket for the inside lever that may help other homeowners facing the same problem.

Our simple restraining bracket works well for a mortise lock that is configured for an exterior thumb-latch and interior lever. The exterior thumb-latch when depressed retracts the latch that keeps the gate closed and when gripped allows you to pull the gate open without using the lever. The same bracket could be made to work on a simple passageway lever using a tubular latch but would only work if the spindle was split so that the exterior lever could retract the latch even when the interior lever is fixed in place by the bracket. The bracket works well for dogs as they lack a thumb to push the bracket down and thus cannot release the lever, but it would not work for dexterous children. The bracket can easily be made by hobbyists using half rod stock which is available at most hardware stores.

Simple bracket hobbyists can make using metal half rod to secure a door lever